GEARS WEIGHT EQUATIONS - GEAR CHAIN WEIGHT CALCULATION

METHODOLOGY
Rejman E., Ph.D.,Eng.
Faculty of Mechanical Engineering Rzeszw University of Technology, Poland
Rejman M.,M.Sc., Eng.
Designer, Turbine Engines Design Department Wytwrnia Sprztu Komunikacyjnego WSK PZL-Rzeszw S.A, Poland

Abstract: Weight is a critical factor in aircraft engine design, where it is required to keep the smallest weight at the same strength
properties. Minimum weight requirements are especially applicable at reduction gearboxes of the turbo propeller engines where high
reduction ratio is required to transmit power from power turbine to the propeller. Depending on the required gear reduction value and
available space different gears arrangements are used. Specific gear arrangements allow to transmit high reduction values at certain weight
of the whole gear chain. The presented in the article methodology allows to size the gears and ratios of the gear chains, while keeping the
lightest possible design, still meeting transmitted power and strength properties requirements. The presented methodology is applicable at
the beginning of design process to judge which gear system will fit the best to specific performance requirements. Gear sizing outputs data
from the preliminary gear chain sizing are the inputs data for the detail design. Methodology is applicable to spur, helical and planetary
gears. Primary criteria to size gear dimension is maximum allowable surface durability factor. Based on the derived formulas there have
been created weight graphs. Graphs show the relationship between gear ratio and weight for different types of gears arrangements and
allow to choose specific type of gear system based on the required ratio.
Keywords: GEAR SIZING, GEAR WEIGHT

1. Introduction
Aircraft engine transmissions systems are assemblies from e) f)
which high reliability and low mass is required. Weight limitations
are related to gearboxes which are used to transmit power and
torque. Gearboxes are one of the heaviest assemblies included in
power transmission systems, thats why mass of the power train is
one of the key factor which has an influence on gear train
arrangement.
The article presents the methodology of gear chain mass sizing
depending on kinematic drive scheme. Presented below
methodology allows to size raw dimensions of the gears with Fig. 1 Typical gears arrangement used in aircraft engine power
respect to required gear ratio, transmitted power and gears contact transmission
strength properties. Experience of authors in gearbox design
indicates that contact stress in gear mesh limits load carrying
capacity of the gearbox. Gearbox scheme depends on the role which it plays in transmission
chain and required transmitted power. Strength and mass
2. Discussion requirements are established by AGMA norm [1]. Design equations
are based on the assumption that the weight of a gear drive is
Gearboxes used in aircraft engines are built from a few typical proportional to the solid rotor volume of the individual gears in the
schemes which are presented in figure 1, in example: offset gears
(a), offset gears with idler (b), offset gears with two idlers (c),
drive, b * d 2 * , where:
double reduction gears (d), multi branch gears (e) and planetary b - width of the gear, d - pitch diameter, gear volume fill factor.
gears (f).
Gear volume fill factor is defined:
a) b)
Vs
=1 (1)
Vp
where: Vp solid gear volume, Vs gear material volume after final
machining.
In gearboxes used in aircraft industry gear volume fill factor
value is from 0.3 to 0.7. When know contact stress relationship it is
c) possible to establish required gears volume, necessary to transmit
d) required load at known gearbox ratio. Relationship between
geometrical dimensions of the gearbox, ratios and power shows
equation [2]:

P * (i + 1)3
a 2 * b = 4,84 * 106 (2)
K * n1 * i

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where: a[mm] axis to axis center distance of the gearbox stage, i0 = i1 *i2 (11)
n d
n1 [1/min] input gear speed i gearbox ratio ; i = 1 = 2 Pitch diameter of the idler gear is
n2 d1
d 2 = d1 * i (12)
P[kW] power on input drive, K surface durability factor.
Experience in gearbox design shows that maximum allowable equation (6) is
surface durability factor should be K=1,5-4 MPa [3][4]. Center
2 2 * T1 i1 + 1 2
distance of mating gears describes relationship: b * d 2 = 2000 * * * i1 (13)
K i1
a = 0.5 * (d1 + d 2 ) = 0.5 * d1 * (1 + i ) (3)
If it is taken under consideration that

After substitution equation (3) into (2) we have: d 3 = i0 * d1

2 P i +1 where d3 - pitch diameter of the output gear, then

b * d1 = 10,62 * 106 * (4)
K * n1 i 2 2 * T1 i1 + 1 2
b * d 3 = 2000 * * * i0 (14)
If power P is written as a function of the torque T K i1
T1 * n1 Assuming that gears in the gearbox are not fully machined, we can
P= [kW] (5) get gearbox mass factor M
9500
3

b *d * i
2
where: T1 [Nm] torque on input gear. 2
i i
1 2 i
then equation (4) will be written : M= i =1
= 1 + + i1 + i1 + i0 + 0 (15)
C i1 i1
2 T1 i + 1
b * d1 = 2000 * * (6) There is only one value of the ratio i1, for given ratio i0, at which
K i function M is minimal, which corresponds to minimal mass of the
Real gear volume Vr1 describes the equation: given gearbox stage.
Calculating derivative of equation (15) and resulting equation is set
* d12 equal to zero we get
Vr1 = * b * 1 (7)
4 2
dM 1 io
Equations (6) and (7) show that gearbox volume is a function of = 1 + 2 * i1 2 2 = 0 (16)
input drive volume Vr1. Weight of the whole gearbox is proportional di1 i1 i1
to the sum of the volume of each gear in the gearbox. Based on that
and after next transformations
equation (6) can be used for pinion drive d 2 = d1 * i , where d2
pitch diameter of pinion drive. Hence 3 2 2
2 * i1 + i1 = i0 + 1 (17)

b1 * d 2 * 2 = b1 * d i * 1
2 2 2
1 (8) For given overall gearbox ratio i0, from equation (17), gearbox input
ratio i1 can be calculated for which mass will be minimal. For
For offset gears (fig.1a) summary weight will be proportional to example at give i0=5 input ratio i1=2.196.
equation:
3. Results of discussion
2
2000 * T1 i + 1
i * bi * d i =
2
* * (1 + i 2 ) (9) Taking into consideration equation (15) it is possible to
i =1 K i calculate mass function, which can be a baseline to compare
different gears arrangement. To be able to estimate gearbox weight
quickly it is necessary to describe presented procedure for different
2000 * T1 gearbox arrangements in graphical form or computer algorithm [5],
If C= then
which allow to take quick decision of kinematic drive scheme at
K minimum weight.
As an example of graphical representation mentioned methodology
b * d * i
2
i i 1 for gears arrangements in fig. 1a, b, c, can be weighted curves
M= = +1+ i + i2 (10) shown in figure 2. Based on fig. 2a it is possible to determine input
C i ratio i1 for given overall ratio i0. From figure 2b mass factor M can
be determined in function of the given overall ratio i0.
b * d * i
2
i i
where M = is a gearbox mass factor. Equation The presented design methodology has also an application for
C other types of gearbox arrangements. Next it will be presented
(10) allows to provide gearbox ratio with minimum mass of the methodology for gears arrangements shown in figure 1 d, e, f.
gears.
Gearbox mass calculation methodology has also application to
evaluate mass of the geartrain with idler gear (fig. 1b). Assuming
that i1 ratio between input gear and idler gear, i2 ratio between
idler and output gear, i0 overall ratio, then

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a) b)

b) Fig. 3 Double reduction gears characteristics : a)minimum weight curves,

b) total weight curves

Table 1: Minimum weight equations

Gearbox type Minimum weight equation
2 2
3 2 * i1 i +1
2 * i1 + = 0
Double reduction i0 + 1 i0 + 1

i0 i0
2 2
3 2 * i1 i0 + 1
Multi branch 2 * i1 + =
i0 + 1 i +1
(four branch) 4 * 0
i0 i0
Fig. 2 Offset gears characteristics: a) minimum weight curves, b) total
weight curves
3 20.4 * (i1 1) 2 + 1
Planetary 2 * i0 + i0 =
Figure 3a shows relationship between overall ratio i0 and input ratio n
i1 for double reduction, multi branch and planetary gear system.
Where: n number of planets, is ratio between plane and sun gear.
Figure 3b allows to find mass factor M and what next, mass of the
gearbox. For gears arrangements showed on figure 1 d, e, f Accordingly mass function M equations are (table 2):
minimum weight equations has been established, which allows to
determine gearbox input ratio i1 for gearbox with minimum weight.
Equations are presented in table 1. Table 2: Total weight equations
a) Gearbox type Total weight equation
2 2
Double 1 2 i i
reduction
1+ + 2 * i1 + i1 + 1 + 0 + i0
i1 i0 i1
2 2
Multi branch 1 1 2 i i i
+ + 2 * i1 + i1 + 1 + 0 + 0
(four branch) 4 4 * i1 i0 4 * i 4

0.4 * (i0 1)
2
1 1 2
+ + is + is +
n n * is n * is
Planetary
0.4 * (i0 1)
2
+
n

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 4. Conclusions
Weight of the gearbox is the basic criteria used in aircraft
industry. Gearbox arrangement at the early phase of the design has
serious impact on the gearbox weight. Application of the gearbox
ratio share methodology for specific gearbox stages allows to
minimize gearbox weight.

5. References
[1]. AGMA 911-A94 Design guidelines for aerospace gearing.
[2]. Di Francesco G., Marini S.: Structural analysis of asymmetrical
teeth: reduction of size and weight. Gear technology, September
1997, p.47-51.
[3]. Dudley D.W.: Handbook of practical gear design. CRC Press,
New York 2002.
[4]. Mller L.: Przekadnie zbate. WNT Warszawa 1996.
[5].Rejman M., Rejman E.: Gearbox weight calculation spreadsheet.
Rzeszw 2010 (not publicized).

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